Cosmetic pad and method for its manufacture

ABSTRACT

A cosmetic pad and a method of manufacturing the same. The cosmetic pad includes a layer of hydroentangled cotton-based fibers that form a coherent, soft and resilient, mildly abrasive, linting-resistant fibrous material body having substantially smooth top and bottom surfaces. During its rotary stamping and cutting from a web, the pad is provided with at least one pressure print in a predetermined location in the material body, the pressure print identically aligned on both the top and bottom surfaces of the material body and defining a compression pattern that extends between the top and bottom surfaces of the material body.

TECHNICAL FIELD

The present invention relates generally to cosmetic pads. Moreparticularly, the invention relates to the construction and performanceof a cotton-based cosmetic pad having a high tensile strength, a highabsorbency and a prolonged material memory.

BACKGROUND

Consumer requirements regarding the function and appearance of cosmeticpads have been researched by many of the principle manufacturers in thefield. The results show that though users want a cosmetic pad thatefficiently removes makeup/nail polish and absorbs the same withoutsmearing, users prefer and are drawn to a cosmetic pad that has a soft,luxurious texture and that presents an esthetically pleasing and higherquality appearance.

Conventional and commercially available pad constructions lack thestructural strength and integrity required for effective cleansing andtreatment. A significant amount of lint is generated by conventionalpads when rubbed, leaving undesirable lint residue on skin or nails whenused to remove makeup or nail polish. Furthermore, conventional padsoften fall apart during use, layers of the pad separating from eachother as pressure is applied and moisture is absorbed.

There is significant prior art which addresses some of these concerns.Kemp in U.S. Pat. No. 3,953,638 discloses multi-ply absorbent wipingproducts comprising two identical pattern-embossed outer plies ofabsorbent fibrous material bonded to a central fibrous absorbent layer.Goodbar in U.S. Pat. No. 4,259,958 discloses a multilayered pad composedof wood pulp fiber. Delvaux discloses in U.S. Pat. No. 4,443,512 anabsorbent article with densified areas comprising a pad of absorbentmaterial sandwiched between a backing sheet and a top sheet. Theabsorbent material is a wood fluff or the like and the absorbent articleis embossed on either side or both sides so that the absorbent materialis compressed in discrete areas.

Gerhartl in U.S. Pat. No. 5,480,699 discloses a three-layered pad withthe two outer layers being embossed and the central layer beingrelatively uncompressed. This product has poor structural integrity anddeposits lint on the user's skin and finger nails during make-up removalor lotion application.

Horn in U.S. Pat. No. 5,302,446 discloses a laminated two-sided skincare wipe which uses more than 50 weight % of thermally fusiblethermoplastic fibers to provide lamination and pad strength. Thiscomposition reduces the absorbency and increases the surfaceabrasiveness excessively.

Ziltener et al. in U.S. Pat. No. 7,192,630 disclose a pad formed of oneor more plies which are connected in their edge region and thus have acompression region on their circumference. This compression region isstamped into the pad at a certain distance from the circumference of thepad, the material fibers directed outward from the compression regionand being so long that they are not rigid but rather slightly flexible.This construction increases the cohesion of the plies and providessofter edges. Unfortunately, significant lint is still generated by thisproduct, and the pad structure breaks down during use.

None of the previously described cosmetic pads and/or pad constructionshave successfully combined the advantages of absorbency, pad strengthand esthetic appeal, while providing an economically viable product.

Consequently, there exists a need in the industry to provide an improvedcosmetic pad.

SUMMARY

It is an object of the present invention to provide a cosmetic padhaving improved efficacy, structural integrity and esthetic appeal.

In accordance with a broad aspect, the present invention provides acosmetic pad comprising a layer of hydroentangled cotton-based fibersforming a coherent, soft and resilient, mildly abrasive,linting-resistant fibrous material body, the material body havingsubstantially smooth top and bottom surfaces; and a pressure print in apredetermined, central location in the material body, the pressure printidentically aligned on both the top and bottom surfaces of the materialbody and defining a compression pattern that extends between the top andbottom surfaces of the material body.

In accordance with another broad aspect, the present invention providesa method of manufacturing a cosmetic pad, the method comprisinghydroentangling cotton fibers to form a web of coherent, soft andresilient, mildly abrasive, linting-resistant fibrous material havingsubstantially smooth top and bottom surfaces; heating the web; andapplying a rotary dye to the heated web for stamping and cutting out aplurality of pads from the web, the step of applying a rotary dye to theheated web including defining at least one identically located pressureprint in each of the plurality of pads simultaneously with the cuttingof the plurality of pads, the pressure print defining a compressionpattern that extends between the top and bottom surfaces of therespective pad.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B show, in top and bottom views respectively, a cosmeticpad, according to a non-limiting example of implementation of thepresent invention;

FIGS. 2A and 2B illustrate a system for the production of the pad shownin FIG. 1, according to a non-limiting example of implementation of thepresent invention; and

FIG. 3 illustrates a rotary dye cut tool, according to an example ofimplementation of the present invention.

DETAILED DESCRIPTION

The present invention is directed to a cosmetic pad having a hightensile strength, a high absorbency and a prolonged material memory, andto a method of constructing the same.

As used herein, the term “cosmetic pad” refers to a pad that can be usedto apply or remove make-up or other cosmetics, cleanse skin surfaces,apply emollients or other liquid materials to the skin, remove nailpolish and similar task.

As used herein, the term “cotton” refers to scoured and bleached cottonfiber wherein a finish has been applied to the cotton surface to permitsubsequent processing. While cotton is a cellulosic fiber, it isdifferentiated from other cellulosic fibers, such as wood pulp, by itsstrength, absorbency and fiber length.

As used herein, the term “pressure print” refers to a defined, visualpattern that is formed in a web, and appears on the web surface, whenrough fiber surfaces within the web are forced together at one or morespecific locations, following a specific pattern, during rotary diestamping.

As used herein, the term “compression pattern” or “compression region”refers to a pattern or region arising in a web as a result ofcompressing web fibers according to a specific design during rotary diestamping and/or cutting, where the rotary die stamping compresses theweb fibers and creates a high frictional bond that holds the compressedweb fibers tightly together in the specific design layout.

The term “machine direction” as used herein refers to the direction oftravel of the forming surface onto which fibers are deposited duringformation of a material.

The term “cross-machine direction” as used herein refers to thedirection in the same plane, which is perpendicular to horizontalmachine direction.

As used herein, the term “machine direction tensile” (hereinafter may bereferred to as “MDT”) is the force applied in the machine direction torupture a sample in substantial accordance with TAPPI test proceduresand may be reported as grams/centimeter of width.

As used herein, the term “cross direction tensile” (hereinafter may bereferred to as “CDT”) is the force applied in the cross direction torupture a sample in substantial accordance with TAPPI test proceduresand may be reported as grams/centimeter of width.

As used herein, the term “basis weight” (hereinafter may be referred toas “BW”) is the weight per unit area of a sample calculated inaccordance with ASTM test procedure D-3776-96, Option C, and may bereported as grams per square meter or abbreviated as gsm.

As used herein, the term “hydroentangle” or “hydroentangling” refers toa process wherein a web of fibrous material consisting of one or moretypes of fibers are subjected to a pattern of high-velocity water jets,which entangle the fibers to achieve mechanical bonding without bindermaterials or thermal bonding.

As used herein, the term “spunlaced fabrics” refers to a web of materialconsisting of one or more types of non-continuous fibers, where thefibers are hydroentangled to achieve mechanical bonding without bindermaterials or thermal bonding.

As used herein, the term “surface cohesion” refers to the resistance ofthe fibers on the surface of the web from being removed by abrasion orrubbing.

FIGS. 1A and 1B illustrate a cosmetic pad, in accordance with anon-limiting example of implementation of the present invention. The pad100 consists of a heavy-weight layer of hydroentangled cotton-basedfibers, which form a coherent, soft and resilient, mildly abrasive,linting-resistant fibrous material body 102. The material body 102 ofthe pad 100 is double-sided, having smooth, unapertured top and bottomsurfaces 104 and 106, respectively. Although the exemplary pad 100 shownin FIGS. 1A and 1B is round in shape, it should be noted that differentpolygonal shapes are possible and included in the scope of theinvention.

The preferred embodiment of a cosmetic pad according to the instantinvention is constructed from an airlaid bleached cotton-based web thathas been hydroentangled such that its outside surfaces are smooth,un-apertured and mildly abrasive. These outer surfaces possess excellentsurface cohesion, which prevents linting during functional use. Theareal basis weight is about 270 gsm (ranging between 260 and 280 gsm)and thus provides significant liquid capacity.

Note that the cotton-based web may be composed of 100% cotton or,alternatively, of a blend of cotton and one or more of various differentmaterials, such as rayon, polypropylene, polyester and microfibres. Thepure cotton itself is characterized by superior absorbency, texturalproperties and very high fiber-to-fiber cohesion. The preferred types ofbleached cotton are cotton staple, cotton comber noils or cotton ginmotes.

The bleached cotton fiber for the preferred embodiment should have thehighest possible level of fiber-to-fiber cohesion for the best padperformance. Using appropriate fiber finish at minimum add-on levelsensures this.

Specific to the present invention, the pad 100 includes a definedpressure print 108 in a predetermined location in the material body 102.As shown in FIGS. 1A, 1B, this predetermined location may, in oneexample, be substantially centered with respect to the pad surface area.Alternatively, the predetermined location may be anywhere on the padsurface.

Note that, in a variant example of implementation, the pad 100 mayinclude a plurality of defined pressure prints, positioned at differentrespect locations on the pad surface area.

The pressure print 108 is identically aligned on both the top and bottomsurfaces 104, 106 and defines a compression pattern that extends betweenthe top and bottom surfaces 104, 106 of the material body 102.

The pad 100 may also include a second, defined pressure print 110 in thematerial body 102, extending along a circumference of the material body102. The pressure print 110 defines a compression region at a radialdistance from the circumference of the material body 102, thecompression region extending between the top and bottom surfaces 104,106 of the material body 102 for defining an edge region of the pad 100.

It has been found that the compression pattern defined in the materialbody 102 of the pad 100 by the pressure print 108 provides an increasedcleaning performance, an increased absorbancy and an extended materialmemory in the pad 100, compared to competitive pads. The compressionpattern enables an optimum inner pad strength, even when moisturized,which provides for a highly absorbent pad. In the case of the extendedmaterial memory, this leads to a longer lasting pad, which does not loseits shape during use.

As will be discussed below, the pressure prints 108 and 110, and thusthe compression patterns/regions, are formed by rotary dye stampingduring the pad forming process. Since the natural surface of scouredcotton fibers is very rough, when these rough fiber surfaces are forcedtogether at specific location(s) (e.g. along an edge or following apredefined pattern) during the die stamping and/or cutting or padforming process, a high frictional bond is created between the fibers,as well as a significant degree of hydrogen bonding, which makes astrong and efficient bond.

Specific to the present invention, the pressure print 108 ischaracterized by a predefined, visually recognizable design. In theexample shown in FIG. 1, the pressure print 108 is in the shape of aflower. Various different designs are possible, without departing fromthe scope of the invention. Advantageously, the visually recognizabledesign of the pressure print 108 contributes to and enhances theesthetic appeal of the cosmetic pad 100, lending a higher qualityappearance to the pad 100 which appeals to consumers.

FIGS. 2A and 2B illustrate a system or machine for manufacturingcosmetic pads, according to a non-limiting example of implementation ofthe present invention. During the manufacturing process, a web orlaminate of hydroentangled cotton-based fibers passes through a padforming system or machine. This web may be pre-formed, presented inindividual roll form and fed off this roll to the pad forming machineor, alternatively, may be formed within the system or machine in a firststage of the pad forming process.

The hydroentanglement process, also known as a spunlace process, is anonwovens manufacturing process that employs high-pressure jets of waterto entangle fibers and thereby provide fabric integrity. Softness,drape, conformability, excellent surface cohesion and high strength arethe major characteristics that make spunlaced nonwoven unique amongnonwovens.

The formed web, usually air-laid or carded, is first compacted andprewetted to eliminate air pockets and then water-needled. The waterpressure generally increases from the first to the last injectors.Pressures as high as 2200 psi are used to direct the water jets onto theweb. This pressure is sufficient for most nonwoven fibers, althoughhigher pressures may be used in specialized applications to achievehigher tensile strength and lock in surface fibers more efficiently.

In general, cotton fibers are preferred for their high strength,pliability, plastic deformation resistance and water insolubility.Cotton fibers are hydrophilic, chemically stable and relativelycolorless. Another advantage is that cotton has an inherent bondingability caused by a high content of hydroxyl groups, which attract watermolecules. As the water evaporates from the fabric, the hydroxyl groupson fiber surface link together by hydrogen bonds.

The web support system or conveyor and collector wire plays an importantpart in most nonwoven processes. This is especially true for thespunlaced process wherein it has a critical role. In this process, thepattern of the final fabric is a direct function of the conveyor wiredesign. By using the appropriate wire web support system, webs with avariety of smooth or apertured surfaces can be created.

Specific to the present invention, a web or laminate of hydroentangledcotton-based fibers with smooth outer surfaces is created, oralternatively received in a roll if pre-formed, and fed into the padforming system or machine. The web is first heated, for example bypassing the web through an embossing roller. Once heated, the web orlaminate is then fed through one or more shear-type rotary dyes forsimultaneous stamping and cutting out of the pads. The pressure appliedby the rotary dyes to the pre-heated web both cuts out a plurality ofpads and, simultaneously, identically stamps or embosses each of theplurality of pads produced.

Note that the cosmetic pads formed may be round, oval or any form ofpolygon in shape.

In a specific, non-limiting example of implementation of the presentinvention, the rotary dye cutting/stamping apparatus and process isdesigned to cut out a plurality of pads and to apply at least oneidentically located pressure print (and thus at least one correspondingcompression pattern extending through the material body), and to sealthe circumferential edge, on each pad produced.

FIG. 3 illustrates a rotary dye tool 300, according to a non-limitingexample of implementation of the present invention. As seen, the rotarydye tool 300 presents on its outer surface a repetitive layout ofshearing edges 302 and stitch patterns. The shearing edges 302 define aplurality of round pads. The edge stitch patterns 304 define thecircumferential edges of each pad, while the design stitch patterns 306define, within each pad, an identically located flower print, forexample. When the pre-heated web of hydrotangled cotton-based fibers ispassed through this rotary dye tool 300 during the pad forming process,the rotary dye tool 300 is operative to dye cut the web into theplurality of pads per the required shape and dimensions defined by theshearing edges 302. Simultaneously with this cutting, the rotary dyetool 300 is operative to stamp or emboss, in each formed pad, an edgepressure print and a floral pressure print, per the edge stitch patterns304 and the design stitch patterns 306, respectively. As a result of therotary dye tool 300 layout, these edge and floral pressure prints areidentically located in each pad, identically aligned on top and bottomsurfaces of the pad.

Effective pressure printing and edge sealing during the pad dye-stampingstage is a function of the shearing and compressive forces and theireffect on the cohesion of the cotton-based fibers making up the pad. Asmentioned above, the rough scoured cotton fiber surfaces, when forcedtogether at specific locations defined by the rotary dye tool, under thetremendous pressure applied by the rotary dye, compress together with ahigh frictional bond and a significant degree of hydrogen bonding. Thepressure delivered by the rotary dye during the forming and cutting ofthe pads results in clearly defined patterns (i.e. the at least onepressure print) in the pads.

Thus, the definition of the pressure print and of the compressionpattern extending through the material body, as well as the sealing ofthe outside edge, of each pad is accomplished by the combination of thehigh shearing and compression forces created during rotarystamping/cutting. The low finish level and the correct moisture contentof the pre-heated web optimize sealing. After stamping, the finishedcosmetic pads are packaged.

The MDT and CDT strengths of the preferred embodiment pads were measuredand were found to be, respectively, 2.4 kg/cm and 1.93 kg/cm of width.Surprisingly, competitive products were found to have significantlylower MD and CD tensile strengths. As an example a major competitiveproduct was found to have MDT and CDT strengths that measured,respectively, 0.35 kg/cm and 0.06 kg/cm of width.

Although various embodiments have been illustrated, this was for thepurpose of describing, but not limiting, the present invention. Variouspossible modifications and different configurations will become apparentto those skilled in the art and are within the scope of the presentinvention, which is defined more particularly by the attached claims.

What is claimed is:
 1. A cosmetic pad comprising: a) a layer ofhydroentangled cotton-based fibers forming a coherent, soft andresilient, mildly abrasive, linting-resistant fibrous material body,said material body having substantially smooth top and bottom surfaces;b) a pressure print in a predetermined, central location in saidmaterial body, said pressure print identically aligned on both said topand bottom surfaces of said material body and defining a compressionpattern that extends between the top and bottom surfaces of saidmaterial body.
 2. A cosmetic pad as defined in claim 1, wherein saidpressure print is a first pressure print, said pad further comprising asecond pressure print in said material body extending along acircumference of said material body, said second pressure print defininga compression region at a radial distance from the circumference of saidmaterial body, said compression region extending between the top andbottom surfaces of said material body.
 3. A cosmetic pad as defined inclaim 1, wherein said layer has an areal weight between 120 and 350grams per square meter.
 4. A cosmetic pad as defined in claim 1, whereinsaid layer has an areal weight of substantially 270 grams per squaremeter.
 5. A cosmetic pad as defined in claim 1, wherein said pad has aminimum tensile strength of 1.2 kilograms per centimeter of said padwidth in any radial direction.
 6. A cosmetic pad as defined in claim 1,wherein said layer is airlaid before hydroentanglement.
 7. A cosmeticpad as defined in claim 1, wherein said material body is characterizedby a polygonal shape.
 8. A cosmetic pad as defined in claim 1, whereinsaid first pressure print is characterized by a predefined, visuallyrecognizable design.
 9. A cosmetic pad as defined in claim 8, whereinsaid first pressure print is in the shape of a flower.
 10. A method ofmanufacturing a cosmetic pad, said method comprising: a) hydroentanglingcotton fibers to form a web of coherent, soft and resilient, mildlyabrasive, linting-resistant fibrous material having substantially smoothtop and bottom surfaces; b) heating the web; c) applying a rotary dye tothe heated web for stamping and cutting out a plurality of pads from theweb, said applying a rotary dye to the heated web including defining atleast one identically located pressure print in each of the plurality ofpads simultaneously with the cutting of the plurality of pads, thepressure print defining a compression pattern that extends between thetop and bottom surfaces of the respective pad.